Top 10 Common Manufacturing Hazards

Importance of Identifying Manufacturing Hazards

In 2022, the US Bureau of Labor Statistics reported a total of 405 work-related deaths in the manufacturing industry. This goes to show how critical safety is in manufacturing operations. Here are six benefits of properly identifying manufacturing hazards:

• Improves Workplace Safety: By accurately identifying hazards, employers can implement appropriate preventive measures to reduce the risk of accidents or injuries in the workplace.
• Reduces Costs: Workplace accidents can result in costly medical expenses, compensation claims, and decreased productivity. Identifying hazards early on can prevent such incidents, saving companies time and money.
• Ensures Compliance With Regulations: The Occupational Safety and Health Administration (OSHA) has strict guidelines and regulations for workplace safety. Properly identifying hazards helps companies comply with these regulations and avoid penalties.
• Enhances Productivity: Companies can maintain productivity by minimizing workplace accidents and injuries. A safe working environment also promotes employee morale, increasing efficiency and motivation.
• Protects Workers’ Health: Manufacturing hazards pose physical risks and impact employees’ long-term health. Proper identification allows for implementing measures to protect workers from exposure to harmful substances or environments.
• Builds a Positive Company Image: Employers who prioritize workplace safety by identifying and managing hazards demonstrate their commitment to their employees’ well-being. This helps attract top talent and improves the company’s overall reputation.

10 Manufacturing Hazards to Watch Out For

Manufacturing safety starts with identifying potential hazards and taking appropriate measures to prevent them. Here are the 10 most common manufacturing hazards that employers and employees should be aware of:

Machine Hazards

Machinery operators and drivers have the third-highest number of serious work-related claims. They’re at high risk of getting injured due to unguarded or inadequately guarded moving parts, such as gears and belts. Inappropriate use of machinery, such as not following safety procedures or using damaged equipment, can also lead to accidents.

How To Reduce the Risk:

• Ensure all machinery has proper guards and barriers to prevent accidental contact with moving parts.
• Regularly inspect and maintain these guards to ensure their effectiveness.
• Provide comprehensive training for employees on safe operation, maintenance, and emergency procedures for all machinery. Highlight the importance of following safety protocols and using equipment as intended.

Chemical Hazards

Employees may be exposed to different chemicals used in manufacturing processes, such as solvents, acids, and gases. Exposure to these substances can cause skin irritation, respiratory problems, and other serious health issues.

How To Reduce the Risk:

• Identify all chemicals in the workplace and provide appropriate training to employees on safely handling, storing, and disposing of them.
• Use less hazardous alternatives where possible and minimize employee exposure by providing proper ventilation systems and personal protective equipment (PPE).

Electrical Hazards

Electrical hazards such as electric shock or electrocution can occur due to faulty wiring, damaged tools, or improper use of electrical equipment. These accidents can result in serious injuries or even death.

How To Reduce the Risk:

• Ensure all electrical equipment is properly maintained and grounded.
• Regularly inspect tools and cords for any damage before use.
• Provide training on safely handling electrical equipment and the importance of following proper procedures, such as locking out/tagging out, when working on or near energized equipment.

Respiratory Hazards

Manufacturing processes can generate hazardous dust, fumes, and vapors that employees may inhale. Prolonged exposure to these substances can cause respiratory issues, lung damage, or even cancer.

How To Reduce the Risk:

• Identify potential respiratory hazards in the workplace and implement control measures such as ventilation systems or PPE.
• Provide respirators and training on their use for tasks where exposure cannot be eliminated.

Ergonomic Hazards

Repetitive motions, awkward postures, heavy lifting, and other ergonomic hazards can lead to musculoskeletal disorders (MSDs) among manufacturing workers. These injuries can significantly impact employee well-being and productivity.

How To Reduce the Risk:

• Evaluate tasks and workstations for ergonomic risk factors and implement solutions to reduce or eliminate them.
• Train employees on proper lifting techniques, taking breaks, and stretching exercises to prevent MSDs.

Noise Hazards

Exposure to high noise levels in manufacturing environments can cause hearing loss and other health issues. Noise hazards are prevalent in workplaces with loud machinery, tools, or processes that produce excessive noise.

How To Reduce the Risk:

• Identify sources of excessive noise and provide appropriate PPE, such as earplugs or earmuffs. Implement engineering controls, such as sound barriers, whenever possible.
• Conduct regular noise assessments to ensure noise levels are within acceptable limits.

Slips, Trips, and Falls

Slips, trips, and falls are the common causes of non-fatal injuries in the manufacturing industry, with an average of 46,000 incidents over three years. These accidents happen due to wet or oily surfaces, cluttered walkways, and uneven floors. They can lead to sprains, strains, fractures, and other injuries.

How To Reduce the Risk:

• Keep work areas clean and free of spills or debris.
• Repair any damaged flooring or stairs promptly.
• Provide proper lighting and mark potential hazards with warning signs to alert employees.

Fire and Explosion Hazards

Manufacturing processes involving flammable materials create fire hazards that could quickly escalate into life-threatening emergencies. Explosions can also occur due to improper storage, handling, or chemical mixing.

How To Reduce the Risk:

• Implement fire safety measures such as regular inspections, proper storage and handling of flammable materials, and a comprehensive emergency response plan.
• Provide training on recognizing warning signs and responding appropriately in case of a fire or explosion.

Forklift and Vehicle Accidents

Forklifts and other vehicles used in manufacturing facilities pose significant hazards to operators and pedestrians. These accidents can result from not following safety protocols, lack of training, or equipment malfunction.

How To Reduce the Risk:

• Ensure all operators are properly trained and certified to operate forklifts and other vehicles.
• Promote safe traffic flow in warehouses by marking designated pedestrian walkways, enforcing speed limits, and conducting regular maintenance checks on all vehicles.

Lockout/Tagout (LOTO) Failures

LOTO procedures prevent unexpected machine startup and protect employees from hazardous energy sources. Failure to follow LOTO procedures can result in serious injuries or fatalities.

How To Reduce the Risk:

• Develop and implement a comprehensive LOTO program, including written policies, training, and regular audits.
• Encourage employees to speak up if they notice deviations from LOTO procedures and promptly address any issues.